ChillerOptimization Savings Fund Expansion Project
Merck integrated tekWorx adaptive control and optimization solution with a planned lab expansion, using the energy savings and utility rebate to help justify the total project.
Facility Bio
- S-6 Plant in Summit, NJ
- New 800,000 ft2 R&D lab
- 7 chillers of varying size, type and age
- 7,800 ton cooling capacity
- 24/7 critical operations
Situation
- Unreliable cooling production required frequent manual intervention
- Traditional Primary- Secondary hydronic system
- Low ΔT, high system pressure and reverse decoupler flow
- CHW distribution loop for new lab load
Solution
- Detailed implementation plan to maintain production
- Convert to full variable flow
- Modulating evap valves for different chiller DPs
- Condenser pump and cooling tower VFDs
- V-ball valves on AHUs to improve distribution flow
- Install PLC-based Control Engine Optimization® system
- Integrate with campus Honeywell EBI system
Results That Exceed Client Expectations
Financial Savings
- $115,000 utility rebate
- $150,000 annual energy savings
- 2-year project payback before rebate
Energy Impact
- 1,250,000 kWh saved annually
- .36 kW/ton efficiency improvement
Operational Benefits
- Fully automated system
- Increased cooling reliability
- Minimized manual intervention
- Lower system pressure and new AHU valves eliminated reverse flow
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